Surgical stapler cartridge with compression features at staple driver edges

ABSTRACT

An apparatus includes a body, a shaft assembly, an end effector, and a staple cartridge. The end effector includes an anvil and a lower jaw. The anvil is pivotable toward the lower jaw to clamp tissue. The staple cartridge is coupled with the lower jaw. The staple cartridge includes a deck, a plurality of staples, and a plurality of staple drivers. The deck faces the anvil. The staples are positioned in a plurality of staple openings formed through the deck. The staple drivers are configured to drive the staples out of the staple openings. Each staple driver of the plurality of staple drivers includes a staple driver body. At least a portion of the staple drivers further include a compressible feature extending from the staple driver body toward the anvil.

BACKGROUND

In some settings, endoscopic surgical instruments may be preferred overtraditional open surgical devices since a smaller incision may reducethe post-operative recovery time and complications. Consequently, someendoscopic surgical instruments may be suitable for placement of adistal end effector at a desired surgical site through the cannula of atrocar. These distal end effectors may engage tissue in a number of waysto achieve a diagnostic or therapeutic effect (e.g., endocutter,grasper, cutter, stapler, clip applier, access device, drug/gene therapydelivery device, and energy delivery device using ultrasonic vibration,RF, laser, etc.). Endoscopic surgical instruments may include a shaftbetween the end effector and a handle portion, which is manipulated bythe clinician. Such a shaft may enable insertion to a desired depth androtation about the longitudinal axis of the shaft, thereby facilitatingpositioning of the end effector within the patient. Positioning of anend effector may be further facilitated through inclusion of one or morearticulation joints or features, enabling the end effector to beselectively articulated or otherwise deflected relative to thelongitudinal axis of the shaft.

Examples of endoscopic surgical instruments include surgical staplers.Some such staplers are operable to clamp down on layers of tissue, cutthrough the clamped layers of tissue, and drive staples through thelayers of tissue to substantially seal the severed layers of tissuetogether near the severed ends of the tissue layers. Merely exemplarysurgical staplers are disclosed in U.S. Pat. No. 4,805,823, entitled“Pocket Configuration for Internal Organ Staplers,” issued Feb. 21,1989; U.S. Pat. No. 5,415,334, entitled “Surgical Stapler and StapleCartridge,” issued May 16, 1995; U.S. Pat. No. 5,465,895, entitled“Surgical Stapler Instrument,” issued Nov. 14, 1995; U.S. Pat. No.5,597,107, entitled “Surgical Stapler Instrument,” issued Jan. 28, 1997;U.S. Pat. No. 5,632,432, entitled “Surgical Instrument,” issued May 27,1997; U.S. Pat. No. 5,673,840, entitled “Surgical Instrument,” issuedOct. 7, 1997; U.S. Pat. No. 5,704,534, entitled “Articulation Assemblyfor Surgical Instruments,” issued Jan. 6, 1998; U.S. Pat. No. 5,814,055,entitled “Surgical Clamping Mechanism,” issued Sep. 29, 1998; U.S. Pat.No. 6,978,921, entitled “Surgical Stapling Instrument Incorporating anE-Beam Firing Mechanism,” issued Dec. 27, 2005; U.S. Pat. No. 7,000,818,entitled “Surgical Stapling Instrument Having Separate Distinct Closingand Firing Systems,” issued Feb. 21, 2006; U.S. Pat. No. 7,143,923,entitled “Surgical Stapling Instrument Having a Firing Lockout for anUnclosed Anvil,” issued Dec. 5, 2006; U.S. Pat. No. 7,303,108, entitled“Surgical Stapling Instrument Incorporating a Multi-Stroke FiringMechanism with a Flexible Rack,” issued Dec. 4, 2007; U.S. Pat. No.7,367,485, entitled “Surgical Stapling Instrument Incorporating aMultistroke Firing Mechanism Having a Rotary Transmission,” issued May6, 2008; U.S. Pat. No. 7,380,695, entitled “Surgical Stapling InstrumentHaving a Single Lockout Mechanism for Prevention of Firing,” issued Jun.3, 2008; U.S. Pat. No. 7,380,696, entitled “Articulating SurgicalStapling Instrument Incorporating a Two-Piece E-Beam Firing Mechanism,”issued Jun. 3, 2008; U.S. Pat. No. 7,404,508, entitled “SurgicalStapling and Cutting Device,” issued Jul. 29, 2008; U.S. Pat. No.7,434,715, entitled “Surgical Stapling Instrument Having MultistrokeFiring with Opening Lockout,” issued Oct. 14, 2008; U.S. Pat. No.7,721,930, entitled “Disposable Cartridge with Adhesive for Use with aStapling Device,” issued May 25, 2010; U.S. Pat. No. 8,408,439, entitled“Surgical Stapling Instrument with An Articulatable End Effector,”issued Apr. 2, 2013; and U.S. Pat. No. 8,453,914, entitled “Motor-DrivenSurgical Cutting Instrument with Electric Actuator Directional ControlAssembly,” issued Jun. 4, 2013. The disclosure of each of theabove-cited U.S. Patents is incorporated by reference herein.

While the surgical staplers referred to above are described as beingused in endoscopic procedures, it should be understood that suchsurgical staplers may also be used in open procedures and/or othernon-endoscopic procedures. By way of example only, a surgical staplermay be inserted through a thoracotomy, and thereby between a patient'sribs, to reach one or more organs in a thoracic surgical procedure thatdoes not use a trocar as a conduit for the stapler. Such procedures mayinclude the use of the stapler to sever and close a vessel leading to alung. For instance, the vessels leading to an organ may be severed andclosed by a stapler before removal of the organ from the thoraciccavity. Of course, surgical staplers may be used in various othersettings and procedures.

Examples of surgical staplers that may be particularly suited or usethrough a thoracotomy are disclosed in U.S. Patent Pub. No.2014/0243801, entitled “Surgical Instrument End Effector ArticulationDrive with Pinion and Opposing Racks,” published Aug. 28, 2014, now U.S.Pat. No. 9,186,142, issued Nov. 17, 2015; U.S. Patent Pub. No.2014/0239041, entitled “Lockout Feature for Movable Cutting Member ofSurgical Instrument,” published Aug. 28, 2014, now U.S. Pat. No.9,717,497, issued Aug. 1, 2017; U.S. Patent Pub. No. 2014/0239042,entitled “Integrated Tissue Positioning and Jaw Alignment Features forSurgical Stapler,” published Aug. 28, 2014, now U.S. Pat. No. 9,517,065,issued Dec. 13, 2016; U.S. Patent Pub. No. 2014/0239036, entitled “JawClosure Feature for End Effector of Surgical Instrument,” published Aug.28, 2014, now U.S. Pat. No. 9,839,421, issued Dec. 12, 2017; U.S. PatentPub. No. 2014/0239040, entitled “Surgical Instrument with ArticulationLock having a Detenting Binary Spring,” published Aug. 28, 2014, nowU.S. Pat. No. 9,867,615, issued Jan. 16, 2018; U.S. Patent Pub. No.2014/0239043, entitled “Distal Tip Features for End Effector of SurgicalInstrument,” published Aug. 28, 2014; now U.S. Pat. No. 9,622,746,issued Apr. 18, 2017; U.S. Patent Pub. No. 2014/0239037, entitled“Staple Forming Features for Surgical Stapling Instrument,” publishedAug. 28, 2014; now U.S. Pat. No. 10,092,292, issued Oct. 9, 2018; U.S.Patent Pub. No. 2014/0239038, entitled “Surgical Instrument withMulti-Diameter Shaft,” published Aug. 28, 2014, now U.S. Pat. No.9,795,379, issued Oct. 24, 2017; and U.S. Patent Pub. No. 2014/0239044,entitled “Installation Features for Surgical Instrument End EffectorCartridge,” published Aug. 28, 2014, now U.S. Pat. No. 9,808,248, issuedNov. 7, 2017. The disclosure of each of the above-cited U.S. PatentApplications is incorporated by reference herein.

While various kinds of surgical stapling instruments and associatedcomponents have been made and used, it is believed that no one prior tothe inventor(s) has made or used the invention described in the appendedclaims.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of this specification, illustrate embodiments of the invention,and, together with the general description of the invention given above,and the detailed description of the embodiments given below, serve toexplain the principles of the present invention.

FIG. 1 depicts a perspective view of an exemplary articulating surgicalstapling instrument;

FIG. 2 depicts a side elevational view of the instrument of FIG. 1;

FIG. 3 depicts a perspective view of an end effector of the instrumentof FIG. 1, with the end effector in a closed configuration;

FIG. 4 depicts a perspective view of the end effector of FIG. 3, withthe end effector in an open configuration;

FIG. 5 depicts an exploded perspective view of the end effector of FIG.3;

FIG. 6 depicts a cross-sectional end view of the end effector of FIG. 3,taken along line 6-6 of FIG. 4;

FIG. 7A depicts a cross-sectional side view of the end effector of FIG.3, taken along line 7-7 of FIG. 4, with a firing beam in a proximalposition;

FIG. 7B depicts a cross-sectional side view of the end effector of FIG.3, taken along line 7-7 of FIG. 4, with the firing beam in a distalposition;

FIG. 8 depicts a perspective view of the end effector of FIG. 3,positioned at tissue and having been actuated once in the tissue;

FIG. 9A depicts a perspective view of an exemplary alternative stapledriver that may be incorporated into a staple cartridge used in the endeffector of FIG. 3;

FIG. 9B depicts a side elevational view of the staple driver of FIG. 9A;

FIG. 10 depicts a side elevational view of another exemplary alternativestaple driver that may be incorporated into a staple cartridge used inthe end effector of FIG. 3;

FIG. 11 depicts a side elevational view of another exemplary alternativestaple driver that may be incorporated into a staple cartridge used inthe end effector of FIG. 3;

FIG. 12 depicts a side elevational view of another exemplary alternativestaple driver that may be incorporated into a staple cartridge used inthe end effector of FIG. 3;

FIG. 13A depicts a cross-sectional end view of an exemplary alternativeend effector incorporating the staple driver of FIG. 9A in multipleform, with a firing beam in a proximal position and staples being in anunfired position;

FIG. 13B depicts a cross-sectional end view of the end effector of FIG.13A, with the firing beam in an intermediate position and staples in anintermediate position;

FIG. 13C depicts a cross-sectional end view of the end effector of FIG.13A, with the firing beam in a distal position and staples in a firedposition;

FIG. 14A depicts a partial, cross-sectional side view of the endeffector of FIG. 13A, taken along line 14A-14A of FIG. 13A, showing astaple in the unfired position;

FIG. 14B depicts a partial, cross-sectional side view of the endeffector of FIG. 13B, taken along line 14B-14B of FIG. 13B, showing thestaple in a first intermediate position; and

FIG. 14C depicts a partial, cross-sectional side view of the endeffector of FIG. 13C, taken along line 14C-14C of FIG. 13C, showing thestaple in a second intermediate position.

The drawings are not intended to be limiting in any way, and it iscontemplated that various embodiments of the invention may be carriedout in a variety of other ways, including those not necessarily depictedin the drawings. The accompanying drawings incorporated in and forming apart of the specification illustrate several aspects of the presentinvention, and together with the description serve to explain theprinciples of the invention; it being understood, however, that thisinvention is not limited to the precise arrangements shown.

DETAILED DESCRIPTION

The following description of certain examples of the invention shouldnot be used to limit the scope of the present invention. Other examples,features, aspects, embodiments, and advantages of the invention willbecome apparent to those skilled in the art from the followingdescription, which is by way of illustration, one of the best modescontemplated for carrying out the invention. As will be realized, theinvention is capable of other different and obvious aspects, all withoutdeparting from the invention. Accordingly, the drawings and descriptionsshould be regarded as illustrative in nature and not restrictive.

I. Exemplary Surgical Stapler

FIG. 1 depicts an exemplary surgical stapling and severing instrument(10) that includes a handle assembly (20), a shaft assembly (30), and anend effector (40). End effector (40) and the distal portion of shaftassembly (30) are sized for insertion, in a nonarticulated state asdepicted in FIG. 1, through a trocar cannula to a surgical site in apatient for performing a surgical procedure. By way of example only,such a trocar may be inserted in a patient's abdomen, between two of thepatient's ribs, or elsewhere. In some settings, instrument (10) is usedwithout a trocar. For instance, end effector (40) and the distal portionof shaft assembly (30) may be inserted directly through a thoracotomy orother type of incision. It should be understood that terms such as“proximal” and “distal” are used herein with reference to a cliniciangripping handle assembly (20) of instrument (10). Thus, end effector(40) is distal with respect to the more proximal handle assembly (20).It will be further appreciated that for convenience and clarity, spatialterms such as “vertical” and “horizontal” are used herein with respectto the drawings. However, surgical instruments are used in manyorientations and positions, and these terms are not intended to belimiting and absolute.

A. Exemplary Handle Assembly and Shaft Assembly

As shown in FIGS. 1-2, handle assembly (20) of the present examplecomprises pistol grip (22), a closure trigger (24), and a firing trigger(26). Each trigger (24, 26) is selectively pivotable toward and awayfrom pistol grip (22) as will be described in greater detail below.Handle assembly (20) further includes an anvil release button (25), afiring beam reverse switch (27), and a removable battery pack (28).These components will also be described in greater detail below. Ofcourse, handle assembly (20) may have a variety of other components,features, and operabilities, in addition to or in lieu of any of thosenoted above. Other suitable configurations for handle assembly (20) willbe apparent to those of ordinary skill in the art in view of theteachings herein.

As shown in FIGS. 1-3, shaft assembly (30) of the present examplecomprises an outer closure tube (32), an articulation section (34), anda closure ring (36), which is further coupled with end effector (40).Closure tube (32) extends along the length of shaft assembly (30).Closure ring (36) is positioned distal to articulation section (34).Closure tube (32) and closure ring (36) are configured to translatelongitudinally relative to handle assembly (20). Longitudinaltranslation of closure tube (32) is communicated to closure ring (36)via articulation section (34). Exemplary features that may be used toprovide longitudinal translation of closure tube (32) and closure ring(36) will be described in greater detail below.

Articulation section (34) is operable to laterally deflect closure ring(36) and end effector (40) laterally away from the longitudinal axis(LA) of shaft assembly (30) at a desired angle (α). End effector (40)may thereby reach behind an organ or approach tissue from a desiredangle or for other reasons. In some versions, articulation section (34)enables deflection of end effector (40) along a single plane. In someother versions, articulation section (34) enables deflection of endeffector along more than one plane. In the present example, articulationis controlled through an articulation control knob (35) which is locatedat the proximal end of shaft assembly (30). Knob (35) is rotatable aboutan axis that is perpendicular to the longitudinal axis (LA) of shaftassembly (30). Closure ring (36) and end effector (40) pivot about anaxis that is perpendicular to the longitudinal axis (LA) of shaftassembly (30) in response to rotation of knob (35). By way of exampleonly, rotation of knob (35) clockwise may cause corresponding clockwisepivoting of closure ring (36) and end effector (40) at articulationsection (34). Articulation section (34) is configured to communicatelongitudinal translation of closure tube (32) to closure ring (36),regardless of whether articulation section (34) is in a straightconfiguration or an articulated configuration.

In some versions, articulation section (34) and/or articulation controlknob (35) are/is constructed and operable in accordance with at leastsome of the teachings of U.S. Pub. No. 2014/0243801, entitled “SurgicalInstrument End Effector Articulation Drive with Pinion and OpposingRacks,” published Aug. 28, 2014, now U.S. Pat. No. 9,186,142, issuedNov. 17, 2015, the disclosure of which is incorporated by referenceherein. Articulation section (34) may also be constructed and operablein accordance with at least some of the teachings of U.S. patentapplication Ser. No. 14/314,125, entitled “Articulation Drive Featuresfor Surgical Stapler,” filed Jun. 25, 2014, published as U.S. PatentPub. No. 2015/0374360 on Dec. 31, 2015, the disclosure of which isincorporated by reference herein; and/or in accordance with the variousteachings below. Other suitable forms that articulation section (34) andarticulation knob (35) may take will be apparent to those of ordinaryskill in the art in view of the teachings herein.

As shown in FIGS. 1-2, shaft assembly (30) of the present examplefurther includes a rotation knob (31). Rotation knob (31) is operable torotate the entire shaft assembly (30) and end effector (40) relative tohandle assembly (20) about the longitudinal axis (LA) of shaft assembly(30). In some versions, rotation knob (31) is operable to selectivelylock the angular position of shaft assembly (30) and end effector (40)relative to handle assembly (20) about the longitudinal axis (LA) ofshaft assembly (30). For instance, rotation knob (31) may betranslatable between a first longitudinal position, in which shaftassembly (30) and end effector (40) are rotatable relative to handleassembly (20) about the longitudinal axis (LA) of shaft assembly (30);and a second longitudinal position, in which shaft assembly (30) and endeffector (40) are not rotatable relative to handle assembly (20) aboutthe longitudinal axis (LA) of shaft assembly (30). Of course, shaftassembly (30) may have a variety of other components, features, andoperabilities, in addition to or in lieu of any of those noted above. Byway of example only, at least part of shaft assembly (30) is constructedin accordance with at least some of the teachings of U.S. Pub. No.2014/0239038, entitled “Surgical Instrument with Multi-Diameter Shaft,”published Aug. 28, 2014, now U.S. Pat. No. 9,795,379, issued Oct. 24,2017, the disclosure of which is incorporated by reference herein. Othersuitable configurations for shaft assembly (30) will be apparent tothose of ordinary skill in the art in view of the teachings herein.

B. Exemplary End Effector

As also shown in FIGS. 1-3, end effector (40) of the present exampleincludes a lower jaw (50) and a pivotable anvil (60). Anvil (60)includes a pair of integral, outwardly extending pins (66) that aredisposed in corresponding curved slots (54) of lower jaw (50). Pins (66)and slots (54) are shown in FIG. 5. Anvil (60) is pivotable toward andaway from lower jaw (50) between an open position (shown in FIGS. 2 and4) and a closed position (shown in FIGS. 1, 3, and 7A-7B). Use of theterm “pivotable” (and similar terms with “pivot” as a base) should notbe read as necessarily requiring pivotal movement about a fixed axis.For instance, in the present example, anvil (60) pivots about an axisthat is defined by pins (66), which slide along curved slots (54) oflower jaw (50) as anvil (60) moves toward lower jaw (50). In suchversions, the pivot axis translates along the path defined by slots (54)while anvil (60) simultaneously pivots about that axis. In addition orin the alternative, the pivot axis may slide along slots (54) first,with anvil (60) then pivoting about the pivot axis after the pivot axishas slid a certain distance along the slots (54). It should beunderstood that such sliding/translating pivotal movement is encompassedwithin terms such as “pivot,” “pivots,” “pivotal,” “pivotable,”“pivoting,” and the like. Of course, some versions may provide pivotalmovement of anvil (60) about an axis that remains fixed and does nottranslate within a slot or channel, etc.

As best seen in FIG. 5, lower jaw (50) of the present example defines achannel (52) that is configured to receive a staple cartridge (70).Staple cartridge (70) may be inserted into channel (52), end effector(40) may be actuated, and then staple cartridge (70) may be removed andreplaced with another staple cartridge (70). Lower jaw (50) thusreleasably retains staple cartridge (70) in alignment with anvil (60)for actuation of end effector (40). In some versions, lower jaw (50) isconstructed in accordance with at least some of the teachings of U.S.Pub. No. 2014/0239044, entitled “Installation Features for SurgicalInstrument End Effector Cartridge,” published Aug. 28, 2014, now U.S.Pat. No. 9,808,248, issued Nov. 7, 2017, the disclosure of which isincorporated by reference herein. Other suitable forms that lower jaw(50) may take will be apparent to those of ordinary skill in the art inview of the teachings herein.

As best seen in FIGS. 4-6, staple cartridge (70) of the present examplecomprises a cartridge body (71) and a tray (76) secured to the undersideof cartridge body (71). The upper side of cartridge body (71) presents adeck (73), against which tissue may be compressed when anvil (60) is ina closed position. Cartridge body (71) further defines a longitudinallyextending channel (72) and a plurality of staple pockets (74). A staple(77) is positioned in each staple pocket (74). A staple driver (75) isalso positioned in each staple pocket (74), underneath a correspondingstaple (77), and above tray (76). As will be described in greater detailbelow, staple drivers (75) are operable to translate upwardly in staplepockets (74) to thereby drive staples (77) upwardly through staplepockets (74) and into engagement with anvil (60). Staple drivers (75)are driven upwardly by a wedge sled (78), which is captured betweencartridge body (71) and tray (76), and which translates longitudinallythrough cartridge body (71). Wedge sled (78) includes a pair ofobliquely angled cam surfaces (79), which are configured to engagestaple drivers (75) and thereby drive staple drivers (75) upwardly aswedge sled (78) translates longitudinally through cartridge (70). Forinstance, when wedge sled (78) is in a proximal position as shown inFIG. 7A, staple drivers (75) are in downward positions and staples (77)are located in staple pockets (74). As wedge sled (78) is driven to thedistal position shown in FIG. 7B by a translating knife member (80),wedge sled (78) drives staple drivers (75) upwardly, thereby drivingstaples (77) out of staple pockets (74) and into staple forming pockets(64). Thus, staple drivers (75) translate along a vertical dimension aswedge sled (78) translates along a horizontal dimension.

It should be understood that the configuration of staple cartridge (70)may be varied in numerous ways. For instance, staple cartridge (70) ofthe present example includes two longitudinally extending rows of staplepockets (74) on one side of channel (72); and another set of twolongitudinally extending rows of staple pockets (74) on the other sideof channel (72). However, in some other versions, staple cartridge (70)includes three, one, or some other number of staple pockets (74) on eachside of channel (72). In some versions, staple cartridge (70) isconstructed and operable in accordance with at least some of theteachings of U. U.S. Pub. No. 2014/0239042, entitled “Integrated TissuePositioning and Jaw Alignment Features for Surgical Stapler,” publishedAug. 28, 2014, now U.S. Pat. No. 9,517,065, issued Dec. 13, 2016, thedisclosure of which is incorporated by reference herein. In addition orin the alternative, staple cartridge (70) may be constructed andoperable in accordance with at least some of the teachings of U.S. Pub.No. 2014/0239044, entitled “Installation Features for SurgicalInstrument End Effector Cartridge,” published Aug. 28, 2014, now U.S.Pat. No. 9,808,248, issued Nov. 7, 2017, the disclosure of which isincorporated by reference herein. Other suitable forms that staplecartridge (70) may take will be apparent to those of ordinary skill inthe art in view of the teachings herein.

As best seen in FIG. 4, anvil (60) of the present example comprises alongitudinally extending channel (62) and a plurality of staple formingpockets (64). Channel (62) is configured to align with channel (72) ofstaple cartridge (70) when anvil (60) is in a closed position. Eachstaple forming pocket (64) is positioned to lie over a correspondingstaple pocket (74) of staple cartridge (70) when anvil (60) is in aclosed position. Staple forming pockets (64) are configured to deformthe legs of staples (77) when staples (77) are driven through tissue andinto anvil (60). In particular, staple forming pockets (64) areconfigured to bend the legs of staples (77) to secure the formed staples(77) in the tissue. Anvil (60) may be constructed in accordance with atleast some of the teachings of U.S. Pub. No. 2014/0239042, entitled“Integrated Tissue Positioning and Jaw Alignment Features for SurgicalStapler,” published Aug. 28, 2014, now U.S. Pat. No. 9,517,065, issuedDec. 13, 2016; at least some of the teachings of U.S. Pub. No.2014/0239036, entitled “Jaw Closure Feature for End Effector of SurgicalInstrument,” published Aug. 28, 2014, now U.S. Pat. No. 9,839,421,issued Dec. 12, 2017; and/or at least some of the teachings of U.S. Pub.No. 2014/0239037, entitled “Staple Forming Features for SurgicalStapling Instrument,” published Aug. 28, 2014, now U.S. Pat. No.10,092,292, issued Oct. 9, 2018, the disclosure of which is incorporatedby reference herein. Other suitable forms that anvil (60) may take willbe apparent to those of ordinary skill in the art in view of theteachings herein.

In the present example, a knife member (80) is configured to translatethrough end effector (40). As best seen in FIGS. 5 and 7A-7B, knifemember (80) is secured to the distal end of a firing beam (82), whichextends through a portion of shaft assembly (30). As best seen in FIGS.4 and 6, knife member (80) is positioned in channels (62, 72) of anvil(60) and staple cartridge (70). Knife member (80) includes a distallypresented cutting edge (84) that is configured to sever tissue that iscompressed between anvil (60) and deck (73) of staple cartridge (70) asknife member (80) translates distally through end effector (40). Asnoted above and as shown in FIGS. 7A-7B, knife member (80) also driveswedge sled (78) distally as knife member (80) translates distallythrough end effector (40), thereby driving staples (77) through tissueand against anvil (60) into formation. Various features that may be usedto drive knife member (80) distally through end effector (40) will bedescribed in greater detail below.

In some versions, end effector (40) includes lockout features that areconfigured to prevent knife member (80) from advancing distally throughend effector (40) when a staple cartridge (70) is not inserted in lowerjaw (50). In addition or in the alternative, end effector (40) mayinclude lockout features that are configured to prevent knife member(80) from advancing distally through end effector (40) when a staplecartridge (70) that has already been actuated once (e.g., with allstaples (77) deployed therefrom) is inserted in lower jaw (50). By wayof example only, such lockout features may be configured in accordancewith at least some of the teachings of U.S. Pub. No. 2014/0239041,entitled “Lockout Feature for Movable Cutting Member of SurgicalInstrument,” published Aug. 28, 2014, now U.S. Pat. No. 9,717,497,issued Aug. 1, 2017, the disclosure of which is incorporated byreference herein; and/or at least some of the teachings of U.S. patentapplication Ser. No. 14/314,108, entitled “Method of Using LockoutFeatures for Surgical Stapler Cartridge,” filed on Jun. 25, 2014,published as U.S. Patent Pub. No. 2015/0374373 on Dec. 31, 2015, thedisclosure of which is incorporated by reference herein. Other suitableforms that lockout features may take will be apparent to those ofordinary skill in the art in view of the teachings herein.Alternatively, end effector (40) may simply omit such lockout features.

C. Exemplary Actuation of Anvil

In the present example, anvil (60) is driven toward lower jaw (50) byadvancing closure ring (36) distally relative to end effector (40).Closure ring (36) cooperates with anvil (60) through a camming action todrive anvil (60) toward lower jaw (50) in response to distal translationof closure ring (36) relative to end effector (40). Similarly, closurering (36) may cooperate with anvil (60) to open anvil (60) away fromlower jaw (50) in response to proximal translation of closure ring (36)relative to end effector (40). By way of example only, closure ring (36)and anvil (60) may interact in accordance with at least some of theteachings of U.S. Pub. No. 2014/0239036, entitled “Jaw Closure Featurefor End Effector of Surgical Instrument,” published Aug. 28, 2014, nowU.S. Pat. No. 9,839,421, issued Dec. 12, 2017, the disclosure of whichis incorporated by reference herein; and/or in accordance with at leastsome of the teachings of U.S. patent application Ser. No. 14/314,108,entitled “Jaw Opening Feature for Surgical Stapler,” filed on Jun. 25,2014, published as U.S. Patent Pub. No. 2015/0374373 on Dec. 31, 2015,the disclosure of which is incorporated by reference herein. Exemplaryfeatures that may be used to provide longitudinal translation of closurering (36) relative to end effector (40) will be described in greaterdetail below.

As noted above, handle assembly (20) includes a pistol grip (22) and aclosure trigger (24). As also noted above, anvil (60) is closed towardlower jaw (50) in response to distal advancement of closure ring (36).In the present example, closure trigger (24) is pivotable toward pistolgrip (22) to drive closure tube (32) and closure ring (36) distally.Various suitable components that may be used to convert pivotal movementof closure trigger (24) toward pistol grip (22) into distal translationof closure tube (32) and closure ring (36) relative to handle assembly(20) will be apparent to those of ordinary skill in the art in view ofthe teachings herein. When closure trigger (24) reaches a fully pivotedstate, such that anvil (60) is in a fully closed position relative tolower jaw (50), locking features in handle assembly (20) lock theposition of trigger (24) and closure tube (32), thereby locking anvil(60) in a fully closed position relative to lower jaw (50). Theselocking features are released by actuation of anvil release button (25).Anvil release button (25) is configured and positioned to be actuated bythe thumb of the operator hand that grasps pistol grip (22). In otherwords, the operator may grasp pistol grip (22) with one hand, actuateclosure trigger (24) with one or more fingers of the same hand, and thenactuate anvil release button (25) with the thumb of the same hand,without ever needing to release the grasp of pistol grip (22) with thesame hand. Other suitable features that may be used to actuate anvil(60) will be apparent to those of ordinary skill in the art in view ofthe teachings herein.

D. Exemplary Actuation of Firing Beam

In the present example, instrument (10) provides motorized control offiring beam (82). In particular, instrument (10) includes motorizedcomponents that are configured to drive firing beam (82) distally inresponse to pivoting of firing trigger (26) toward pistol grip (22). Insome versions, a motor (not shown) is contained in pistol grip (22) andreceives power from battery pack (28). This motor is coupled with atransmission assembly (not shown) that converts rotary motion of a driveshaft of the motor into linear translation of firing beam (82). In somesuch versions, firing beam (82) may only be advanced distally when anvil(60) is in a fully closed position relative to lower jaw (50). Afterfiring beam (82) is advanced distally to sever tissue and drive staples(77) as described above with reference to FIGS. 7A-7B, the driveassembly for firing beam (82) may be automatically reversed to drivefiring beam (82) proximally back to the retracted position (e.g., backfrom the position shown in FIG. 7B to the position shown in FIG. 7A).Alternatively, the operator may actuate firing beam reverse switch (27),which may reverse the drive assembly for firing beam (82) in order toretract firing beam (82) to a proximal position. Handle assembly (20) ofthe present example further includes a bailout feature (21), which isoperable to provide a mechanical bailout allowing the operator tomanually retract firing beam (82) proximally (e.g., in the event ofpower loss while firing beam (82) is in a distal position, etc.).

By way of example only, the features that are operable to providemotorized actuation of firing beam (82) may be configured and operablein accordance with at least some of the teachings of U.S. Pat. No.8,210,411, entitled “Motor-Driven Surgical Instrument,” issued Jul. 3,2012, the disclosure of which is incorporated by reference herein. Asanother merely illustrative example, the features that are operable toprovide motorized actuation of firing beam (82) may be configured andoperable in accordance with at least some of the teachings of U.S. Pat.No. 8,453,914, entitled “Motor-Driven Surgical Cutting Instrument withElectric Actuator Directional Control Assembly,” issued Jun. 4, 2013,the disclosure of which is incorporated by reference herein. As yetanother merely illustrative example, the features that are operable toprovide motorized actuation of firing beam (82) may be configured andoperable in accordance with at least some of the teachings of U.S.patent application Ser. No. 14/226,142, entitled “Surgical InstrumentComprising a Sensor System,” filed Mar. 26, 2014, now U.S. Pat. No.9,913,642, issued Mar. 13, 2018, the disclosure of which is incorporatedby reference herein.

Other suitable components, features, and configurations that may be usedto provide motorization of firing beam (82) will be apparent to those ofordinary skill in the art in view of the teachings herein. It shouldalso be understood that some other versions may provide manual drivingof firing beam (82), such that a motor may be omitted. By way of exampleonly, firing beam (82) may be manually actuated in accordance with atleast some of the teachings of any other reference cited herein.

FIG. 8 shows end effector (40) having been actuated through a singlestroke through tissue (90). As shown, cutting edge (84) (obscured inFIG. 8) has cut through tissue (90), while staple drivers (75) havedriven two alternating rows of staples (77) through the tissue (90) oneach side of the cut line produced by cutting edge (84). Staples (77)are all oriented substantially parallel to the cut line in this example,though it should be understood that staples (77) may be positioned atany suitable orientations. In the present example, end effector (40) iswithdrawn from the trocar after the first stroke is complete, the spentstaple cartridge (70) is replaced with a new staple cartridge (70), andend effector (40) is then again inserted through the trocar to reach thestapling site for further cutting and stapling. This process may berepeated until the desired amount of cuts and staples (77) have beenprovided. Anvil (60) may need to be closed to facilitate insertion andwithdrawal through the trocar; and anvil (60) may need to be opened tofacilitate replacement of staple cartridge (70).

It should be understood that cutting edge (84) may cut tissuesubstantially contemporaneously with staples (77) being driven throughtissue during each actuation stroke. In the present example, cuttingedge (84) just slightly lags behind driving of staples (77), such that astaple (47) is driven through the tissue just before cutting edge (84)passes through the same region of tissue, though it should be understoodthat this order may be reversed or that cutting edge (84) may bedirectly synchronized with adjacent staples. While FIG. 8 shows endeffector (40) being actuated in two layers (92, 94) of tissue (90), itshould be understood that end effector (40) may be actuated through asingle layer of tissue (90) or more than two layers (92, 94) of tissue.It should also be understood that the formation and positioning ofstaples (77) adjacent to the cut line produced by cutting edge (84) maysubstantially seal the tissue at the cut line, thereby reducing orpreventing bleeding and/or leaking of other bodily fluids at the cutline. Furthermore, while FIG. 8 shows end effector (40) being actuatedin two substantially flat, apposed planar layers (92, 94) of tissue, itshould be understood that end effector (40) may also be actuated acrossa tubular structure such as a blood vessel, a section of thegastrointestinal tract, etc. FIG. 8 should therefore not be viewed asdemonstrating any limitation on the contemplated uses for end effector(40). Various suitable settings and procedures in which instrument (10)may be used will be apparent to those of ordinary skill in the art inview of the teachings herein.

It should also be understood that any other components or features ofinstrument (10) may be configured and operable in accordance with any ofthe various references cited herein. Additional exemplary modificationsthat may be provided for instrument (10) will be described in greaterdetail below. Various suitable ways in which the below teachings may beincorporated into instrument (10) will be apparent to those of ordinaryskill in the art. Similarly, various suitable ways in which the belowteachings may be combined with various teachings of the references citedherein will be apparent to those of ordinary skill in the art. It shouldalso be understood that the below teachings are not limited toinstrument (10) or devices taught in the references cited herein. Thebelow teachings may be readily applied to various other kinds ofinstruments, including instruments that would not be classified assurgical staplers. Various other suitable devices and settings in whichthe below teachings may be applied will be apparent to those of ordinaryskill in the art in view of the teachings herein.

II. Exemplary Alternative Staple Drivers

End effector (40) may be structured to provide a predefined gapseparating the surface of cartridge deck (73) and the correspondingsurface of anvil (60) when anvil (60) is in a closed position. In someinstances, cutting and stapling tissue may be challenging if thethickness of the target tissue differs from this predefined gapdistance. For example, if the target tissue is significantly thickerthan the gap, an operator may have trouble firing the instrument toeffectively cut and staple the tissue. On the other hand, if the targettissue is thinner than the gap between the cartridge deck and the anvil,it may be difficult to maintain the position of the target tissuebetween anvil (60) and deck (73). Particularly, during firing, as knifemember (80) advances against the tissue, the tissue may shift positionwithin the jaws of the instrument, thereby making it challenging toeffectively cut the target tissue. In some instances, staples (77) aredriven through regions of tissue before knife member (80) reaches thesame regions of tissue, such that the legs of staples (77) are disposedin the tissue before that region of tissue is severed. In such instanceswhere the tissue is so thin that the tissue is not being held in placedue to compression between anvil (60) and deck (73), knife member (80)may plow the tissue rather than cutting it cleanly, which may result instaples (77) tearing through the tissue through a cheese wire effect.

In view of the foregoing, it may be desirable to provide one or morefeatures in end effector (40) that compress relatively thin tissue tothereby secure the tissue as knife member (80) is actuated. Suchcompression of tissue may prevent undesirable movement of tissue thatmight otherwise occur when the tissue is positioned between a closedanvil (60) and deck (73). Several examples of tissue compressionfeatures are described in greater detail below, while other exampleswill be apparent to those of ordinary skill in the art in view of theteachings herein.

FIGS. 9A-12 show exemplary alternative staple drivers (175, 275, 375,475), each of which may be readily incorporated into staple cartridge(70) in place of staple driver (75). Staple drivers (175, 275, 375, 475)are configured to operate in a substantially similar manner as stapledriver (75). That is, staple drivers (175, 275, 375, 475) are configuredto be incorporated into a staple cartridge of a surgical instrument,such as staple cartridge (70) of surgical instrument (10). For example,staple drivers (175, 275, 375, 475) are configured to be received, alongwith a staple (77), in a plurality of staple pockets (74) of a staplecartridge (70) of a lower jaw (50), and are configured to be drivenupwardly by wedge sled (78) in response to longitudinal advancement offiring beam (82). Therefore, staple drivers (175, 275, 375, 475) areconfigured to drive staples (77) upwardly through staple pockets (74)and into engagement with anvil (60) in the same manner as described withrespect to staple drivers (75). However, staple drivers (175, 275, 375,475) of the present example further include compressible features thatare configured to hold portions of tissue in place during stapling andsevering of tissue.

FIGS. 9A-9B and 13A-14C show staple driver (175). It will be appreciatedby persons skilled in the art that in some examples, a staple cartridge(70) may include a plurality of staple drivers (175), according to thenumber of staples (77) and staple pockets (74) for example. However, insome other examples, a staple cartridge (70) may include any combinationor number of staple drivers (75, 175, 275, 375, 475) or other suitablestaple drivers, as will be apparent to persons skilled in the art inview of the teachings herein. FIGS. 13A-14C show a plurality of stapledrivers (175) incorporated into an exemplary alternative end effector(140). As discussed in further detail below, end effector (140) isconfigured to be incorporated into a surgical instrument, such assurgical instrument (10), and is configured to operate substantiallysimilar to end effector (40).

As shown, staple driver (175) includes a body (176) and a supportportion (178) that is configured to support a crown portion (77 a)(FIGS. 14A-14C) of a staple (77). Staple driver (175) further comprisesa compressible feature (180) that is configured to hold portions oftissue in place during stapling and severing of tissue, as discussed infurther detail below. In the example shown, compressible feature (180)comprises a pair of arcuate members (182 a, 182 b) on opposing sides ofbody (176). As shown, each arcuate member extends substantially from oneend of staple driver (175) to another end of staple driver (175). Stapledriver (175) includes a set of openings (184) between arcuate members(182 a, 182 b) that, as discussed in further detail below, allow arcuatemembers (182 a, 182 b) to deflect in a downward direction toward body(176). Arcuate members (182 a, 182 b) are configured and positioned suchthat crown portion (77 a) may freely pass between arcuate members (182a, 182 b) to reach and rest against support portion (178) as staple (77)is seated on staple driver (175).

In the example shown, arcuate members (182 a, 182 b) each comprise anelastomer, polymer, and/or other suitable material. In the exampleshown, arcuate members (182 a, 182 b) are co-molded with staple driver(175) such that arcuate members (182 a, 182 b) are integral with body(176) of staple driver (175). In some examples, arcuate members (182 a,182 b) may be overmolded onto body (176) of staple driver (175).Alternatively, arcuate members (182 a, 182 b) may be fixed to body (176)of staple driver (175) by other suitable methods that will be apparentto persons skilled in the art in view of the teachings herein. Arcuatemembers (182 a, 182 b) are configured to be rigid enough to urge tissuetoward and against anvil (60) once a staple (77) associated with stapledriver (175) has been partially fired; but compressible enough so as notto prevent the associated staple (77) from being fired completely, aswill be discussed in further detail below. Other suitable configurationsof compressible feature (180) will be apparent to persons skilled in theart in view of the teachings herein.

FIG. 10 shows another exemplary alternative staple driver (275). It willbe appreciated by persons skilled in the art that in some examples, astaple cartridge (70) may include a plurality of staple drivers (275),according to the number of staples (77) and staple pockets (74) forexample. However, in some other examples, a staple cartridge (70) mayinclude any combination of staple drivers (75, 175, 275, 375, 475) orsuitable other suitable staple drivers, as will be apparent to personsskilled in the art in view of the teachings herein.

It will be appreciated that FIG. 10 shows a side view of staple driver(275) (similar to the side view of staple driver (175) shown in FIG.9B). As shown, staple driver (275) includes a body (276) and issubstantially similar to staple driver (175), except that staple driver(275) includes a differently shaped compressible feature (280). Inparticular, compressible feature (280) of this example comprisesopposing bridge members (282 a). While only one bridge member (282 a) isshown, it will be appreciated that staple driver (275) includes asubstantially identical second bridge member opposing bridge member (282a), with the two bridge members (282 a) being configured and positionedsuch that crown portion (77 a) may freely pass between bridge members(282 a) to reach and rest against a support portion (278) as staple (77)is seated on staple driver (275). As shown in the present example,bridge member (282 a) includes a pair of opposing vertical members (284)and a horizontal member (286) extending therebetween. Staple driver(275) further includes support portion (278) (shown in hidden lines)configured to support a crown portion (77 a) (FIGS. 14A-14C) of a staple(77).

In the example shown, bridge members (282 a) each comprise an elastomer,polymer, and/or other suitable material as will be apparent to personsskilled in the art in view of the teachings herein. In the exampleshown, bridge members (282 a, not shown) are co-molded with stapledriver (275) such that bridge members (282 a, not shown) are integralwith body (276) of staple driver (275). In some examples, bridge members(282 a) may be overmolded onto body (276) of staple driver (275).Alternatively, bridge members (282 a) may be fixed to body (276) ofstaple driver (275) by other suitable methods that will be apparent topersons skilled in the art in view of the teachings herein. Bridgemembers (282 a) are configured to be rigid enough to urge tissue towardanvil (60) once a staple (77) associated with staple driver (275) hasbeen partially fired; but compressible enough so as not to prevent theassociated staple (77) from being fired completely, as will be discussedin further detail below. Other suitable configurations of compressiblefeature (280) will be apparent to persons skilled in the art in view ofthe teachings herein.

FIG. 11 shows another exemplary alternative staple driver (375). It willbe appreciated by persons skilled in the art that, in some examples, astaple cartridge (70) may include a plurality of staple drivers (275),according to the number of staples (77) and staple pockets (74) forexample. However, in some other examples, a staple cartridge (70) mayinclude any combination of staple drivers (75, 175, 275, 375, 475) orsuitable other suitable staple drivers, as will be apparent to personsskilled in the art in view of the teachings herein.

It will be appreciated that FIG. 11 shows a side view of staple driver(375) (similar to the side views of staple driver (175, 275) shown inFIGS. 9B and 10). As shown, staple driver (375) includes a body (376)and is substantially similar to staple driver (175), except that stapledriver (375) includes a differently shaped compressible feature (380).In particular, compressible feature (380) of this example comprisesopposing arcuate members (382 a). While only one arcuate member (382 a)is shown, it will be appreciated that staple driver (375) includes asubstantially identical arcuate member opposing arcuate member (382 a),with the two arcuate members (382 a) being configured and positionedsuch that crown portion (77 a) may freely pass between arcuate members(382 a) to reach and rest against a support portion (378) as staple (77)is seated on staple driver (375). As shown, compressible feature (380)is shaped similarly to compressible feature (180), except that arcuatemembers (382 a) are solid such that they do not include an opening likeopening (184). Staple driver (375) further includes support portion(378) (shown in hidden lines) configured to support a crown portion (77a) (FIGS. 14A-14C) of a staple (77).

In the example shown, arcuate members (382 a) each comprise anelastomer, polymer, and/or other suitable material as will be apparentto persons skilled in the art in view of the teachings herein. In theexample shown, arcuate members (382 a) are co-molded with staple driver(375) such that arcuate members (382 a) are integral with body (376) ofstaple driver (375). In some examples, arcuate members (382 a) may beovermolded onto body (376) of staple driver (375). Alternatively,arcuate members (382 a) may be fixed to body (376) of staple driver(375) by other suitable methods that will be apparent to persons skilledin the art in view of the teachings herein. Arcuate members (382 a) areconfigured to be rigid enough to urge tissue toward anvil (60) once astaple (77) associated with staple driver (375) has been partiallyfired; but compressible enough so as not to prevent the associatedstaple (77) from being fired completely, as will be discussed in furtherdetail below. Other suitable configurations of compressible feature(380) will be apparent to persons skilled in the art in view of theteachings herein.

FIG. 12 shows another exemplary alternative staple driver (475). It willbe appreciated by persons skilled in the art that, in some examples, astaple cartridge (70) may include a plurality of staple drivers (475),according to the number of staples (77) and staple pockets (74) forexample. However, in some other examples, a staple cartridge (70) mayinclude any combination of staple drivers (75, 175, 275, 375, 475) orsuitable other staple drivers, as will be apparent to persons skilled inthe art in view of the teachings herein.

It will be appreciated that FIG. 12 shows a side view of staple driver(475) (similar to the side views of staple driver (175, 275, 375) shownin FIGS. 9B, 10, and 11). As shown, staple driver (475) includes a body(476) and is substantially similar to staple driver (175), except thatstaple driver (475) includes a differently shaped compressible feature(480). In particular, compressible feature (480) of this examplecomprises opposing sets of compressible fingers (482). While only oneset of four compressible fingers (482 a) is shown, it will beappreciated that staple driver (475) includes a substantially identicalset of compressible fingers (not shown) opposing compressible fingers(482 a), with both opposing sets of compressible fingers (482 a)configured and positioned such that crown portion (77 a) may freely passbetween the opposing sets of fingers (482 a) to reach and rest against asupport portion (478) as staple (77) is seated on staple driver (475).Staple driver (475) further includes support portion (478) (shown inhidden lines) configured to support a crown portion (77 a) (FIGS.14A-14C) of a staple (77).

In the example shown, compressible fingers (482 a) each comprise anelastomer, polymer, or other suitable material as will be apparent topersons skilled in the art in view of the teachings herein. In theexample shown, compressible fingers (482 a, not shown) are co-moldedwith staple driver (475) such that compressible fingers (482 a, notshown) are integral with body (476) of staple driver (475). In someexamples, compressible fingers (482 a) may be overmolded onto body (476)of staple driver (475). Alternatively, compressible fingers (482 a) maybe fixed to body (476) of staple driver (475) by other suitable methodsthat will be apparent to persons skilled in the art in view of theteachings herein. Compressible fingers (482 a, not shown) are configuredto be rigid enough to urge tissue toward anvil (60) once a staple (77)associated with staple driver (475) has been partially fired, butcompressible such that they compress and do not hamper the associatedstaple (77) from being fired, as will be discussed in further detailbelow. Suitable other configurations of compressible feature (480) willbe apparent to persons skilled in the art in view of the teachingsherein.

As discussed above, FIGS. 13A-14C show an exemplary alternative endeffector (140) that includes a version of staple cartridge (70)incorporating a plurality of staple drivers (175). As also discussedabove, end effector (140) may be readily incorporated into surgicalinstrument (10) in place of end effector (40). As shown, two layers (92,94) of tissue (90) are positioned between anvil (60) and lower jaw (50).By way of example only, the two layers (92, 94) may be provided byopposing walls of a single anatomical structure, such as a large vessel,a section of the gastrointestinal tract, a section of a lung or otherorgan, and/or any other suitable anatomical structure.

In the example shown, the combined thickness of the layers (92, 94) oftissue (90) in the region between cartridge deck (73) and anvil (60) isless than the predefined gap distance between anvil (60) and cartridgedeck (73) with anvil (60) in the closed position. FIGS. 13A and 14A showstaples (77) prior to being fired; FIGS. 13B and 14B show staples (77)in a first partially fired state; and FIGS. 13C and 14C show staples(77) in a second partially fired state. In FIGS. 13A and 14A, firingbeam (82) has not yet advanced to a position whereby wedge sled (78) isin contact with staple drivers (175). Thus, staple drivers (175) are ina retracted position within staple pockets (74). As shown, when stapledrivers are in the retracted position, compressible member (180) liesbelow cartridge deck (73) and thus does not yet contact tissue (90). Atthis stage, even though anvil (60) is in a closed position, tissue (90)may still move between anvil (60) and cartridge deck (73) since thecombined thickness of the layers (92, 94) of tissue (90) in the regionbetween cartridge deck (73) and anvil (60) is less than the predefinedgap distance between anvil (60) and cartridge deck (73) with anvil (60)in the closed position.

As firing beam (82) advances longitudinally, and as shown in FIGS. 13Band 14B, wedge sled (78) advances into contact with staple drivers(175), driving staple drivers (175) and staples (77) upwardly towardanvil (60). Eventually, compressible feature (180) extends abovecartridge deck (73) such that compressible members (182 a, 182 b)contact tissue (90), and compress tissue (90) against anvil (60) aswedge sled (78) drives staple drivers (175) further upwardly. Asdiscussed above, compressible feature (180) is configured to be rigidenough to urge the tissue (90) toward anvil (60) and compress the tissue(90) against anvil (60). It should be understood that, in thelongitudinal region of cartridge (70) where compressible feature (180)is compressing tissue (90) against anvil (60), knife member (80) has notyet severed the corresponding region of tissue (90). In other words,compressible features (180) will compress the tissue (90) against anvil(60) before knife member (80) reaches that particular region of tissue(90).

As wedge sled (78) continues to move longitudinally, staple drivers(175) eventually reach a position where staples (77) are fully fired. Inother words, staples (77) are fully driven into staple forming pockets(64) to deform into a B-shape as understood in the art, with arcuatemembers (182 a, 182 b) continuing to urge tissue (90) against anvil(60). As discussed above and shown in FIGS. 13C and 14C, arcuate members(182 a, 182 b) are compressible a sufficient amount so as not to hamperthe full firing of the associated staple (77). As shown, as firing beam(82) advances further longitudinally, knife member (80) severs tissuesubstantially contemporaneously with the completion of firing of thestaples (77), as discussed in detail above with respect to end effector(40). This process may be repeated until the desired amount of cuts andstaples (77) have been provided. In some versions, the state shown inFIG. 14C constitutes a fully fired state. In some other versions, thestate shown in FIG. 14C constitutes a second partially fired state. Insuch versions, the depicted staple (77) may be further deformed tocontinue forming a “B” shape as arcuate members (182 a, 182 b) continueto urge tissue (90) against anvil (60).

It should be understood from the foregoing that compressible features(180) will prevent the tissue (90) from sliding between deck (73) andanvil (60) as knife member (80) is being driven through the tissue.Compressible features (180) thus cooperate with anvil (60) to securelyhold the tissue (90) for cutting by knife member (80), even though thethickness of tissue (90) is smaller than the predefined gap formedbetween deck (73) and closed anvil (60). It should also be understoodthat compressible features (180) provide pressure against tissue (90) ina highly localized fashion, right at the regions of tissue (90) wherestaples (77) will be driven through tissue (90). This localizedapplication of compression may prevent tissue (90) from sliding relativeto staples (77) as staples (77) are being driven through tissue (90),which may further prevent staples (77) from unnecessarily tearingthrough the tissue (90) by laterally impinging on the tissue (90) in acheese wire effect as staples (77) are being driven through tissue (90).

In the present example, and as shown in FIGS. 13A and 14A, compressiblefeatures (180) are sized and configured such that compressible features(180) are recessed below the surface of deck (73) when staple drivers(175) are in a non-actuated state. In some other versions, compressiblefeatures (180) are sized and configured such that at least a portion ofcompressible features (180) protrude above the surface of deck (73) whenstaple drivers (175) are in a non-actuated state. In such versions, endeffector (140) may be used as a tissue grasper by selectively openingand closing anvil (60), even with thin tissue structures, withoutnecessarily firing knife member (80). Other suitable ways in whichstaple drivers (175) may be varied and used will be apparent to those ofordinary skill in the art in view of the teachings herein.

III. Exemplary Combinations

The following examples relate to various non-exhaustive ways in whichthe teachings herein may be combined or applied. It should be understoodthat the following examples are not intended to restrict the coverage ofany claims that may be presented at any time in this application or insubsequent filings of this application. No disclaimer is intended. Thefollowing examples are being provided for nothing more than merelyillustrative purposes. It is contemplated that the various teachingsherein may be arranged and applied in numerous other ways. It is alsocontemplated that some variations may omit certain features referred toin the below examples. Therefore, none of the aspects or featuresreferred to below should be deemed critical unless otherwise explicitlyindicated as such at a later date by the inventors or by a successor ininterest to the inventors. If any claims are presented in thisapplication or in subsequent filings related to this application thatinclude additional features beyond those referred to below, thoseadditional features shall not be presumed to have been added for anyreason relating to patentability.

Example 1

An apparatus comprising: (a) a body; (b) a shaft assembly extendingdistally from the body; (c) an end effector, wherein the end effectorcomprises: (i) an anvil, and (ii) a lower jaw, wherein the anvil ispivotable toward the lower jaw to clamp tissue; and (d) a staplecartridge coupled with the lower jaw, wherein the staple cartridgecomprises: (i) a deck facing the anvil, (ii) a plurality of staplespositioned in a plurality of staple openings formed through the deck,and (iii) a plurality of staple drivers configured to drive the staplesout of the staple openings, wherein each staple driver of the pluralityof staple drivers comprises a staple driver body, wherein at least aportion of the staple drivers further comprise a compressible featureextending from the staple driver body toward the anvil.

Example 2

The apparatus of Example 1, wherein each compressible feature comprisesan arcuate member.

Example 3

The apparatus of any one or more of Examples 1 through 2, wherein eachstaple driver body has a first end and a second end, wherein thecorresponding arcuate member extends from the first end to the secondend.

Example 4

The apparatus of Example 3, wherein each staple driver further defines agap under the corresponding arcuate member, wherein the gap isconfigured to accommodate deformation of the arcuate member.

Example 5

The apparatus of any one or more of Examples 1 through 4, wherein eachstaple driver further comprises a staple support portion, wherein eachcompressible feature comprises opposing compressible members positionedon each side of the corresponding staple support feature.

Example 6

The apparatus of any one or more of Examples 1 through 5, wherein thecompressible features each comprise an elastomeric material.

Example 7

The apparatus of any one or more of Examples 1 through 6, wherein thecompressible features are configured to deform in response tocompression of tissue by the compressible features against the anvil.

Example 8

The apparatus of any one or more of Examples 1 through 7, wherein eachcompressible feature is configured to transition from an unfiredposition to a fired position, wherein each compressible feature isconfigured to protrude past the anvil in the fired position, wherein thefired position is associated with the corresponding staple driver bodydriving an associated staple against the anvil.

Example 9

The apparatus of Example 8, wherein each compressible feature isconfigured to be recessed relative to the deck in the unfired position,wherein the fired position is associated with the associated staple alsobeing recessed relative to the deck.

Example 10

The apparatus of any one or more of Examples 1 through 9, furthercomprising a firing bar configured to move through the end effector,wherein the firing bar is configured to drive the staple drivers towardthe anvil to move the staples toward a fired position.

Example 11

The apparatus of Example 10, wherein firing bar is further configured tosever tissue as the firing bar drives the staple drivers toward theanvil.

Example 12

The apparatus of Example 11, wherein the compressible features areconfigured to compress tissue against the anvil as the firing bar seversthe tissue.

Example 13

The apparatus of any one or more of Examples 1 through 12, wherein eachof the compressible features comprises a pair of members extendingupwardly from the staple driver body.

Example 14

The apparatus of Example 13, wherein the pair of members are configuredand positioned to receive a portion of a corresponding staple of theplurality of staples between the members of the pair of members.

Example 15

The apparatus of any one or more of Examples 1 through 14, wherein eachcompressible member comprises a pair of legs and a bridge extendingbetween the pair of legs.

Example 16

The apparatus of any one or more of Examples 1 through 15, wherein eachcompressible member comprises a set of fingers.

Example 17

A staple cartridge for use with an end effector of a surgical stapler,the staple cartridge comprising: (a) a cartridge body, wherein thecartridge body includes a cartridge deck, wherein the cartridge bodyfurther defines a plurality of staple openings passing through thecartridge deck; (b) a plurality of staples associated with the pluralityof staple openings; (c) a plurality of staple drivers associated withthe plurality of staple openings and the plurality of staples, whereinthe staple drivers are configured to move toward the cartridge deck todrive the staples out of the staple openings; and (d) a plurality ofcompressible features associated with at least some of the plurality ofstaple drivers, wherein the compressible features are movable with theassociated staple drivers.

Example 18

The staple cartridge of Example 17, wherein the compressible featuresare configured to be driven through the staple openings and compresstissue against an anvil as the staples are driven through the tissue andinto the anvil.

Example 19

A method of using a surgical instrument, wherein the surgical instrumentcomprises: (a) an end effector, wherein the end effector comprises: (i)an anvil, and (ii) a lower jaw, wherein the anvil is configured to movetoward and away from the lower jaw, (iii) a staple cartridge disposed inthe lower jaw, wherein the staple cartridge comprises: (A) a pluralityof staples, and (B) a plurality of staple drivers, each staple driverbeing associated with a corresponding staple of the plurality ofstaples, wherein each staple driver includes an integral compressiblefeature; and (b) a firing member configured to advance through the endeffector to drive the staple drivers toward the anvil, the methodcomprising: (a) positioning tissue between the anvil and the lower jaw;(b) moving the anvil toward the jaw to place the anvil a closedposition; and (c) advancing the firing member through the end effector,wherein advancement of the firing member moves the staples toward theanvil, wherein advancement of the firing member further drives thecompressible feature of each staple driver into contact with a portionof the tissue, wherein the compressible feature compresses thecorresponding portion of tissue against the anvil.

Example 20

The method of Example 19, wherein the compressible feature of eachstaple driver deforms as the compressible feature compresses thecorresponding portion of tissue against the anvil.

IV. Miscellaneous

It should be understood that any one or more of the teachings,expressions, embodiments, examples, etc. described herein may becombined with any one or more of the other teachings, expressions,embodiments, examples, etc. that are described herein. Theabove-described teachings, expressions, embodiments, examples, etc.should therefore not be viewed in isolation relative to each other.Various suitable ways in which the teachings herein may be combined willbe readily apparent to those of ordinary skill in the art in view of theteachings herein. Such modifications and variations are intended to beincluded within the scope of the claims.

It should be appreciated that any patent, publication, or otherdisclosure material, in whole or in part, that is said to beincorporated by reference herein is incorporated herein only to theextent that the incorporated material does not conflict with existingdefinitions, statements, or other disclosure material set forth in thisdisclosure. As such, and to the extent necessary, the disclosure asexplicitly set forth herein supersedes any conflicting materialincorporated herein by reference. Any material, or portion thereof, thatis said to be incorporated by reference herein, but which conflicts withexisting definitions, statements, or other disclosure material set forthherein will only be incorporated to the extent that no conflict arisesbetween that incorporated material and the existing disclosure material.

Versions of the devices described above may have application inconventional medical treatments and procedures conducted by a medicalprofessional, as well as application in robotic-assisted medicaltreatments and procedures. By way of example only, various teachingsherein may be readily incorporated into a robotic surgical system suchas the DAVNCI™ system by Intuitive Surgical, Inc., of Sunnyvale, Calif.Similarly, those of ordinary skill in the art will recognize thatvarious teachings herein may be readily combined with various teachingsof any of the following: U.S. Pat. No. 5,792,135, entitled “ArticulatedSurgical Instrument For Performing Minimally Invasive Surgery WithEnhanced Dexterity and Sensitivity,” issued Aug. 11, 1998, thedisclosure of which is incorporated by reference herein; U.S. Pat. No.5,817,084, entitled “Remote Center Positioning Device with FlexibleDrive,” issued Oct. 6, 1998, the disclosure of which is incorporated byreference herein; U.S. Pat. No. 5,878,193, entitled “Automated EndoscopeSystem for Optimal Positioning,” issued Mar. 2, 1999, the disclosure ofwhich is incorporated by reference herein; U.S. Pat. No. 6,231,565,entitled “Robotic Arm DLUS for Performing Surgical Tasks,” issued May15, 2001, the disclosure of which is incorporated by reference herein;U.S. Pat. No. 6,783,524, entitled “Robotic Surgical Tool with UltrasoundCauterizing and Cutting Instrument,” issued Aug. 31, 2004, thedisclosure of which is incorporated by reference herein; U.S. Pat. No.6,364,888, entitled “Alignment of Master and Slave in a MinimallyInvasive Surgical Apparatus,” issued Apr. 2, 2002, the disclosure ofwhich is incorporated by reference herein; U.S. Pat. No. 7,524,320,entitled “Mechanical Actuator Interface System for Robotic SurgicalTools,” issued Apr. 28, 2009, the disclosure of which is incorporated byreference herein; U.S. Pat. No. 7,691,098, entitled “Platform Link WristMechanism,” issued Apr. 6, 2010, the disclosure of which is incorporatedby reference herein; U.S. Pat. No. 7,806,891, entitled “Repositioningand Reorientation of Master/Slave Relationship in Minimally InvasiveTelesurgery,” issued Oct. 5, 2010, the disclosure of which isincorporated by reference herein; U.S. Pub. No. 2013/0012957, entitled“Automated End Effector Component Reloading System for Use with aRobotic System, published Jan. 10, 2013, now U.S. Pat. No. 8,844,789,issued Sep. 30, 2014, the disclosure of which is incorporated byreference herein; U.S. Pub. No. 2012/0199630, entitled“Robotically-Controlled Surgical Instrument with Force-FeedbackCapabilities,” published Aug. 9, 2012, now U.S. Pat. No. 8,820,605,issued Sep. 2, 2014, the disclosure of which is incorporated byreference herein; U.S. Pub. No. 2012/0132450, entitled “Shiftable DriveInterface for Robotically-Controlled Surgical Tool,” published May 31,2012, now U.S. Pat. No. 8,616,431, issued Dec. 31, 2013, the disclosureof which is incorporated by reference herein; U.S. Pub. No.2012/0199633, entitled “Surgical Stapling Instruments with Cam-DrivenStaple Deployment Arrangements,” published Aug. 9, 2012, now U.S. Pat.No. 8,573,461, issued Nov. 5, 2013, the disclosure of which isincorporated by reference herein; U.S. Pub. No. 2012/0199631, entitled“Robotically-Controlled Motorized Surgical End Effector System withRotary Actuated Closure Systems Having Variable Actuation Speeds,”published Aug. 9, 2012, now U.S. Pat. No. 8,602,288, issued Dec. 10,2013, the disclosure of which is incorporated by reference herein; U.S.Pub. No. 2012/0199632, entitled “Robotically-Controlled SurgicalInstrument with Selectively Articulatable End Effector,” published Aug.9, 2012, now U.S. Pat. No. 9,301,759, issued Apr. 5, 2016, thedisclosure of which is incorporated by reference herein; U.S. Pub. No.2012/0203247, entitled “Robotically-Controlled Surgical End EffectorSystem,” published Aug. 9, 2012, now U.S. Pat. No. 8,783,541, issuedJul. 22, 2014, the disclosure of which is incorporated by referenceherein; U.S. Pub. No. 2012/0211546, entitled “Drive Interface forOperably Coupling a Manipulatable Surgical Tool to a Robot,” publishedAug. 23, 2012, now U.S. Pat. No. 8,479,969, issued Jul. 9, 2013; U.S.Pub. No. 2012/0138660, entitled “Robotically-Controlled Cable-BasedSurgical End Effectors,” published Jun. 7, 2012, now U.S. Pat. No.8,800,838, issued Aug. 12, 2014, the disclosure of which is incorporatedby reference herein; and/or U.S. Pub. No. 2012/0205421, entitled“Robotically-Controlled Surgical End Effector System with RotaryActuated Closure Systems,” published Aug. 16, 2012, now U.S. Pat. No.8,573,465, issued Nov. 5, 2013, the disclosure of which is incorporatedby reference herein.

Versions of the devices described above may be designed to be disposedof after a single use, or they can be designed to be used multipletimes. Versions may, in either or both cases, be reconditioned for reuseafter at least one use. Reconditioning may include any combination ofthe steps of disassembly of the device, followed by cleaning orreplacement of particular pieces, and subsequent reassembly. Inparticular, some versions of the device may be disassembled, and anynumber of the particular pieces or parts of the device may beselectively replaced or removed in any combination. Upon cleaning and/orreplacement of particular parts, some versions of the device may bereassembled for subsequent use either at a reconditioning facility, orby a user immediately prior to a procedure. Those skilled in the artwill appreciate that reconditioning of a device may utilize a variety oftechniques for disassembly, cleaning/replacement, and reassembly. Use ofsuch techniques, and the resulting reconditioned device, are all withinthe scope of the present application.

By way of example only, versions described herein may be sterilizedbefore and/or after a procedure. In one sterilization technique, thedevice is placed in a closed and sealed container, such as a plastic orTYVEK bag. The container and device may then be placed in a field ofradiation that can penetrate the container, such as gamma radiation,x-rays, or high-energy electrons. The radiation may kill bacteria on thedevice and in the container. The sterilized device may then be stored inthe sterile container for later use. A device may also be sterilizedusing any other technique known in the art, including but not limited tobeta or gamma radiation, ethylene oxide, or steam.

Having shown and described various embodiments of the present invention,further adaptations of the methods and systems described herein may beaccomplished by appropriate modifications by one of ordinary skill inthe art without departing from the scope of the present invention.Several of such potential modifications have been mentioned, and otherswill be apparent to those skilled in the art. For instance, theexamples, embodiments, geometries, materials, dimensions, ratios, steps,and the like discussed above are illustrative and are not required.Accordingly, the scope of the present invention should be considered interms of the following claims and is understood not to be limited to thedetails of structure and operation shown and described in thespecification and drawings.

We claim:
 1. An apparatus comprising: (a) a body; (b) a shaft assemblyextending distally from the body; (c) an end effector, wherein the endeffector comprises: (i) an anvil, and (ii) a lower jaw, wherein theanvil is pivotable toward the lower jaw to clamp tissue; and (d) astaple cartridge coupled with the lower jaw, wherein the staplecartridge comprises: (i) a deck facing the anvil, (ii) a plurality ofstaples positioned in a plurality of staple openings formed through thedeck, and (iii) a plurality of staple drivers configured to drive thestaples out of the staple openings, wherein each staple driver of theplurality of staple drivers comprises: (A) a staple driver bodyincluding a support portion configured to support a staple of theplurality of staples, and (B) at least first and second compressiblefeatures extending from the staple driver body toward the anvil, whereineach of the first and second compressible features is positioned andconfigured to protrude past the deck and directly contact tissue andthereby compress the contacted tissue against the anvil when the stapledrivers are driven to a deployed position, wherein the staple of theplurality of staples is configured to be laterally interposed betweenthe first and second compressible features, wherein the firstcompressible feature is independently compressible relative to thesecond compressible feature.
 2. The apparatus of claim 1, wherein eachcompressible feature comprises an arcuate member.
 3. The apparatus ofclaim 2, wherein each staple driver body has a first end and a secondend, wherein the corresponding arcuate member extends from the first endto the second end.
 4. The apparatus of claim 2, wherein each arcuatemember defines a gap disposed between a top surface of the staple driverbody and a bottom surface of the corresponding arcuate member, whereinthe gap is configured to accommodate deformation of the arcuate memberby decreasing in size as the arcuate member compresses.
 5. The apparatusof claim 1, wherein the compressible features each comprise anelastomeric material.
 6. The apparatus of claim 1, wherein thecompressible features are configured to deform in response tocompression of tissue by the compressible features against the anvil. 7.The apparatus of claim 1, wherein each compressible feature isconfigured to transition from an unfired position to a fired position,wherein each compressible feature is configured to protrude past theanvil in the fired position, wherein the fired position is associatedwith the corresponding staple driver body driving an associated stapleagainst the anvil.
 8. The apparatus of claim 7, wherein eachcompressible feature is configured to be recessed relative to the deckin the unfired position, wherein the fired position is associated withthe associated staple also being recessed relative to the deck.
 9. Theapparatus of claim 1, further comprising a firing bar configured to movethrough the end effector, wherein the firing bar is configured to drivethe staple drivers toward the anvil to move the staples toward a firedposition.
 10. The apparatus of claim 9, wherein firing bar is furtherconfigured to sever tissue as the firing bar drives the staple driverstoward the anvil.
 11. The apparatus of claim 10, wherein thecompressible features are configured to compress tissue against theanvil as the firing bar severs the tissue.
 12. The apparatus of claim 1,wherein each compressible member comprises a pair of legs and a bridgeextending between the pair of legs.
 13. The apparatus of claim 1,wherein each compressible member comprises a set of vertically extendingfingers.
 14. A staple cartridge for use with an end effector of asurgical stapler, the staple cartridge comprising: (a) a cartridge body,wherein the cartridge body includes a cartridge deck, wherein thecartridge body further defines a plurality of staple openings passingthrough the cartridge deck; (b) a plurality of staples associated withthe plurality of staple openings; (c) a plurality of staple driversassociated with the plurality of staple openings and the plurality ofstaples, wherein the staple drivers are configured to move toward thecartridge deck to drive the staples out of the staple openings; and (d)a plurality of compressible features associated with at least some ofthe plurality of staple drivers, wherein the compressible features aremovable with the associated staple drivers, wherein the compressiblefeatures are configured to deform toward the corresponding stapledrivers in response to the compressible features pressing directlyagainst tissue, wherein at least one of the compressible featuresincludes first and second compressible arcuate members extending towardthe cartridge deck, wherein a staple of the plurality of staples isconfigured to be laterally interposed between the first and secondcompressible arcuate members, wherein the first and second compressiblearcuate members are arced at a central portion toward the cartridgedeck.
 15. The staple cartridge of claim 14, wherein the compressiblefeatures are configured to be driven through the staple openings andcompress tissue against an anvil as the staples are driven through thetissue and into the anvil.
 16. An apparatus comprising: (a) a body; (b)a shaft assembly extending distally from the body; (c) an end effector,wherein the end effector comprises: (i) an anvil, and (ii) a lower jaw,wherein the anvil is pivotable toward the lower jaw to clamp tissue; and(d) a staple cartridge coupled with the lower jaw, wherein the staplecartridge comprises: (i) a deck facing the anvil, (ii) a plurality ofstaples positioned in a plurality of staple openings formed through thedeck, and (iii) a plurality of staple drivers configured to drive thestaples out of the staple openings, wherein each staple driver of theplurality of staple drivers comprises: (A) a staple driver body, and (B)first and second compressible features extending from the staple driverbody toward the anvil, wherein each staple laterally interposed betweenthe first and second compressible features, wherein each of the firstand second compressible features is configured to transition between anon-deflected configuration when not in contact with the tissue and adeflected configuration when in direct contact with the tissue, whereinthe first compressible feature is independently compressible relative tothe second compressible feature.
 17. The apparatus of claim 16, whereineach pair of compressible features is configured to releasably grasp thecorresponding staple associated with the pair of compressible features.18. The apparatus of claim 14, wherein the first and second compressiblearcuate members each comprise an elastomeric material.
 19. The apparatusof claim 16, wherein each of the first and second compressible featureseach comprise an elastomeric material.